What are the safety precautions for air compressors

Analysis of safety precautions for air compressors

1. Equipment safety protection

1. safety device arrangement
   • Air compressors need to be equipped with pressure gauges, safety valves and over-temperature protection devices. The range of the pressure gauge should be 1.5-3 times the rated working pressure, the diameter of the dial should not be less than 100mm, and should be verified every six months. The opening pressure of the safety valve must not exceed 1.1 times the design pressure, and must be tested regularly to ensure its sensitivity and reliability.
   • Protective covers or railings must be installed on rotating parts such as couplings and belt drives to prevent mechanical damage caused by personal contact.
2. Electrical system safety
   • Electrical equipment should ensure effective grounding and zero-connection protection, and lines should be inspected regularly to prevent aging, short circuit or insulation damage. When the motor and compressor are running, monitor current, voltage and other parameters, and stop the machine for inspection immediately if any abnormalities are found.

2. Operating safety specifications

1. Operator qualifications
   • Operators must undergo professional training, be familiar with equipment structure, performance and safety operation procedures, and obtain special operation operation qualification certificates before taking up their posts.
2. preflight check
   • Before starting up, check whether the connection of each component is loose, whether the amount of lubricating oil is sufficient, and whether the cooling system is normal. Only after confirming that there is no pressure in the air tank can you start the equipment.
3. operation monitoring
   • Pressure, temperature and other parameters should be paid close attention to during operation. The exhaust temperature for single cylinders shall not exceed 190℃, and for double cylinders shall not exceed 160℃. If abnormal sounds, vibrations, pressure gauges and safety valves are found to fail, the machine should be shut down immediately for maintenance.
4. Safe operation ban
   • It is prohibited to work at the compressor outlet, stay, or blow people with compressed air. It is strictly forbidden to smoke or approach open flames when refueling. No repair work shall be carried out while the equipment is in operation.

3. Environmental safety requirements

1. installation environment
   • Air compressors should be installed in places with good ventilation and far away from flammable, explosive materials and corrosive substances. When using in the open air, measures to prevent rain, snow and exposure should be taken.
2. Channels and lighting
   • The surroundings of the equipment should be kept clean and the channels should be unobstructed. When natural lighting is insufficient, artificial lighting should be set up with an illuminance of no less than 30lx.

4. Maintenance system

1. regular maintenance
   • Develop a detailed maintenance plan and regularly replace lubricants, oil filters, air filters and other components. Lubricating oil needs to be replaced every 4000 hours or every year depending on the operating environment. The oil filter needs to be replaced after 300-500 hours of first use, and then replaced every 2000 hours.
2. cleaning and inspection
   • Regularly clean the cooler, drain condensate, and check the tightness of the belt and the operating status of the electrical system, gas path system, and lubrication system. If any faults or abnormalities are found, they should be dealt with in a timely manner and recorded.

V. Safety Management System

1. equipment archives management
   • Establish equipment safety technical files, including design documents, manufacturing units, product quality certificates, use and maintenance instructions and other documents, as well as installation technical documents and materials. Regular inspection records, daily use records, etc. also need to be filed and managed.
2. periodic inspection
   • In accordance with the requirements of the Special Equipment Safety Supervision Regulations, regular inspection applications are submitted to the equipment testing center. Equipment that has not been regularly inspected or fails inspection shall not continue to be used.
3. emergency plan
   • Formulate emergency rescue plans and clarify emergency rescue organizations and responsible persons. Conduct regular emergency drills and training to ensure that operators are familiar with emergency response procedures.

6. Emergency response measures

1. emergency stop
   • In the event of a fault or abnormal situation, the operator should immediately stop the vehicle and cut off the power supply. At the same time, report to relevant personnel and prohibit unauthorized disposal or repair of equipment.
2. accident handling
   • In case of equipment failure or accident, the power and air supply should be quickly cut off and reported to the relevant competent department immediately. Emergency rescue personnel need to be familiar with the emergency rescue plan and carry out emergency rescue work in accordance with the requirements of the plan.

VII. Personnel training and assessment

1. safety training
   • Regularly provide safety training to operators to improve their safety awareness and operating skills. The training content should include equipment structure, working principles, safety operating procedures, emergency response measures, etc.
2. Assessment and evaluation
   • After the training, the operators should be assessed to check their mastery of the training content. Regularly conduct safety assessments for operators to understand safety hazards and loopholes in their operations, and make suggestions for improvement.

8. Safety protection equipment and personal protection

1. personal protective equipment
   • Operators should wear personal protective equipment such as helmets, protective glasses, and protective gloves to ensure their own safety.
2. safety warning signs
   • Set up obvious safety warning signs around the compressor equipment to remind others to pay attention to safety.

9. Compliance with safety regulations and standards

1. compliance
   • The installation, use, and maintenance of air compressors should comply with the requirements of relevant national laws, regulations and standards, such as the “Special Equipment Safety Supervision Regulations” and the “Pressure Vessel Safety Technical Supervision Regulations”.
2. standard update
   • Pay attention to the update of relevant regulations and standards, promptly adjust equipment safety management measures, and ensure that equipment always meets the latest safety requirements.

X. Construction of safety culture

1. Improved safety awareness
   • Improve the safety awareness of all employees through training, publicity and other means, so that safety becomes everyone’s conscious action.
2. implementation of safety responsibilities
   • Clarify the safety responsibilities of personnel at all levels, establish a safety reward and punishment mechanism, and encourage employees to actively participate in safety management.

Through the implementation of the above measures, the operating safety of air compressors can be effectively improved, the risk of accidents can be reduced, and the safety of personnel and equipment can be ensured.